U.S. patent number 8,414,308 [Application Number 13/042,317] was granted by the patent office on 2013-04-09 for electrical connectors for building integrable photovoltaic modules.
This patent grant is currently assigned to Miasole. The grantee listed for this patent is Michael C. Meyers. Invention is credited to Michael C. Meyers.
United States Patent |
8,414,308 |
Meyers |
April 9, 2013 |
Electrical connectors for building integrable photovoltaic
modules
Abstract
Provided are novel building integrable photovoltaic (BIP)
modules having flexible connectors and methods of interconnecting
thereof. According to various embodiments, a BIP module includes
one or more photovoltaic cells positioned on a support sheet and
two or more electrical connectors attached to the support sheet. At
least two conductive elements of these connectors are electrically
coupled to the photovoltaic cells. One connector includes a
connector body and an arm, which allows the connector body to move
with respect to the support sheet at least in a direction
perpendicular to the support sheet. This flexibility may be used to
electrically interconnect modules as well as other purposes.
Another connector also has a connector body, which may be flexibly
or rigidly attached to the same support sheet. Positioning two
connectors on opposite edges of the module allows forming a row of
electrically interconnected modules.
Inventors: |
Meyers; Michael C. (San Jose,
CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Meyers; Michael C. |
San Jose |
CA |
US |
|
|
Assignee: |
Miasole (Santa Clara,
CA)
|
Family
ID: |
47999161 |
Appl.
No.: |
13/042,317 |
Filed: |
March 7, 2011 |
Current U.S.
Class: |
439/67 |
Current CPC
Class: |
H02S
40/36 (20141201); H01R 12/79 (20130101); H01L
31/05 (20130101); H01R 2103/00 (20130101); Y02E
10/50 (20130101); H02S 20/23 (20141201); H01R
13/5219 (20130101); H01R 12/592 (20130101) |
Current International
Class: |
H01R
12/00 (20060101) |
Field of
Search: |
;439/67,492 ;136/44 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Dinh; Phuong
Attorney, Agent or Firm: Weaver Austin Villeneuve &
Sampson LLP
Claims
What is claimed is:
1. A building integrable photovoltaic module comprising: one or
more photovoltaic cells positioned on a support sheet having a
planar surface; a first connector comprising a first connector body
and a first arm, the first arm mechanically connecting the first
connector body to the support sheet, the first connector body
movable with respect to the support sheet at least in a direction
perpendicular to the planar surface of the support sheet to form an
electrical connection with an adjacent building integrable
photovoltaic module, the first connector body comprising a first
conductive element electrically coupled to the one or more
photovoltaic cells; and a second connector comprising a second
connector body attached to the support sheet, the second connector
body comprising a second conductive element electrically coupled to
the one or more photovoltaic cells, the second connector configured
to form an electrical connection with a second adjacent building
integrable photovoltaic module.
2. The building integrable photovoltaic module of claim 1, wherein
the first arm comprises an extension of the support sheet.
3. The building integrable photovoltaic module of claim 1, wherein
the first arm comprises a flexible material and a flexible
conductive pathway that allow the first arm to bend along a length
of the first arm in the direction perpendicular to the planar
surface of the support sheet.
4. The building integrable photovoltaic module of claim 1, wherein
the first arm comprising a pivoting axis at an interface with the
support sheet.
5. The building integrable photovoltaic module of claim 1, wherein
the first connector body and/or the first arm comprises one or more
of the following materials: polyethylene terephthalate,
polybutylene terephthalate, polyphenylene sulfide, polyamide,
polycarbonate, and polypropylene.
6. The building integrable photovoltaic module of claim 1, wherein
the first arm is sufficiently flexible to allow the first connector
body to move at least about 1 millimeter with respect to the
support sheet in a direction parallel to a length of the first arm,
while maintaining the electrical connection between building
integrable photovoltaic module and the adjacent building integrable
photovoltaic module.
7. The building integrable photovoltaic module of claim 1, wherein
the first arm is sufficiently flexible to allow the first connector
body to move by at least about 1 millimeter with respect to the
support sheet in a direction perpendicular to a length of the first
arm and parallel to the planar surface, while maintaining the
electrical connection between building integrable photovoltaic
module and the adjacent building integrable photovoltaic
module.
8. The building integrable photovoltaic module of claim 1, wherein
the first connector body comprises a cavity configured to fit
snugly over an adjacent second connector body of the second
adjacent building integrable photovoltaic module.
9. The building integrable photovoltaic module of claim 8, wherein
the cavity has an opening facing towards the planar surface during
installation.
10. The building integrable photovoltaic module of claim 8, wherein
the first conductive element comprises a pin positioned within the
cavity and wherein the first connector body and/or the second
connector body comprises one or more interlocking features.
11. The building integrable photovoltaic module of claim 1, wherein
the first connector body and/or the second connector body comprises
one or more sealing features.
12. The building integrable photovoltaic module of claim 1, wherein
the first connector body further comprises an additional conductive
element that is not electrically connected to the one or more
photovoltaic cells.
13. The building integrable photovoltaic module of claim 1, wherein
the first connector and the second connector are parts of a
moisture flap extending along a side of the one or more
photovoltaic cells.
14. The building integrable photovoltaic module of claim 1, wherein
the second connector body is attached to the support sheet using a
second arm.
15. The building integrable photovoltaic module of claim 14,
wherein the second arm is sufficiently flexible to allow the second
connector body to move at least about 1 millimeter with respect to
the support sheet in a direction parallel to a length of the second
arm, while maintaining the electrical connection between building
integrable photovoltaic module and the second adjacent building
integrable photovoltaic module.
16. The building integrable photovoltaic module of claim 14,
wherein the second arm is sufficiently flexible to allow the second
connector body to move by at least about 1 millimeter with respect
to the support sheet in a direction perpendicular to a length of
the second arm and parallel to the planar surface, while
maintaining the electrical connection between building integrable
photovoltaic module and the second adjacent building integrable
photovoltaic module.
17. A method for installing a photovoltaic array, the method
comprising (a) providing a first building integrable photovoltaic
module positioned on a building structure, the first building
integrable photovoltaic module comprising a first connector having
a first connector body and a first arm, the first arm mechanically
connecting the first connector body to a first support sheet, the
first connector body movable with respect to the first support
sheet at least in a direction perpendicular to a planar surface of
the first support sheet, the first connector body comprising a
first conductive element electrically coupled to a first set of
photovoltaic cells; and (b) providing a second building integrable
photovoltaic module comprising a second connector comprising a
second connector body attached to a second support sheet, the
second connector body comprising a second conductive element
electrically coupled to a second set of photovoltaic cells; and (c)
positioning the first connector body over the second connector body
to form an electrical connection between the first conductive
element and the second conductive element.
18. The method of claim 17, wherein the first building integrable
photovoltaic module is movable with respect to the second building
integrable photovoltaic module in one or more direction parallel to
the planar surface of the first support sheet without interfering
with the electrical connection between the first conductive element
and the second conductive element.
19. The method of claim 17, further comprising dispensing a sealing
material and/or an adhesive material between the first connector
body and the second connector body prior to positioning the first
connector body over the second connector body.
20. The method of claim 17, further comprising attaching the first
support sheet and/or the second support sheet to the building
structure.
Description
BACKGROUND
Photovoltaic cells are widely used for electricity generation with
one or more photovoltaic cells typically sealed within and
interconnected in a module. Multiple modules may be arranged into
photovoltaic arrays used to convert solar energy into electricity
by the photovoltaic effect. Arrays can be installed on building
rooftops and are used to provide electricity to the buildings and
to the general grid.
SUMMARY
Provided are novel building integrable photovoltaic (BIP) modules
having flexible connectors and methods of their interconnection.
According to various embodiments, a BIP module includes one or more
photovoltaic cells positioned on a support sheet and two or more
electrical connectors attached to the support sheet. At least two
conductive elements of these connectors are electrically coupled to
the photovoltaic cells. One connector includes a connector body and
an arm, which allows the connector body to move with respect to the
support sheet at least in a direction perpendicular to the support
sheet. This flexibility may be used to electrically interconnect
modules as well as for other purposes. Another connector also has a
connector body, which may be flexibly or rigidly attached to the
same support sheet. Positioning two connectors on opposite edges of
the module allows forming a row of electrically interconnected
modules.
In certain embodiments, a BIP module includes one or more
photovoltaic cells positioned on a support sheet as well as a first
connector and a second connector attached to the sheet. The sheet
is defined by a planar surface. The first connector includes a
connector body and an arm, which mechanically connects the body to
the sheet and allows the body to move with respect to the sheet at
least in a direction perpendicular to the planar surface. This
flexibility of the first connector may be used to form an
electrical connection with an adjacent module. The body also
includes one or more conductive elements, one of which is
electrically coupled to the photovoltaic cells. The second
connector also includes a connector body (i.e., a second connector
body) attached to the support sheet. The second connector body
includes one or more conductive elements, one of which is
electrically coupled to the photovoltaic cells. The second
connector is configured to form an electrical connection with yet
another adjacent module. In certain embodiments, the second
connector is also movable with respect to the support sheet and may
have an arm connecting the second connector body to the support
sheet.
An arm of the connector may be an extension of the support sheet.
For example, the support sheet may have a partial cut defining an
arm and separating it from the rest of the support sheet. In the
same or other embodiments, an arm may be made from a flexible
material and contain one or more flexible conductive pathways. This
configuration allows the arm to bend along its length in a
direction perpendicular to the support sheet and/or other
directions. An arm may be made formed as a thin strip of a polymer
material with one or more metal bus bars extending within and
surrounded by the polymer material. In the same or other
embodiments, an arm may include a pivoting axis, for example, at
the interface with the support sheet.
In certain embodiments, an arm is sufficiently flexible to allow
the connector body to move at least about 1 millimeter with respect
to the support sheet in a direction parallel to a length of the
arm. In the same or other embodiments, flexibility of the arm
allows the connector body to move at least about 1 millimeter with
respect to the support sheet in a direction that is perpendicular
to the arm's length and at the same time parallel to the support
sheet. One or both connectors may have arms with such flexibility.
If two arms of adjacent interconnected modules have such
flexibility, then one module may move with respect to the other
module twice the distance listed above. Arms' flexibilities and
movements do not interfere with the electrical connection between
the modules.
A connector body may be made from one or more of rigid materials.
Some examples of rigid materials include polyethylene terephthalate
(e.g., RYNITE.RTM. available from Du Pont in Wilmington, Del.),
polybutylene terephthalate (e.g., CRASTIN.RTM. also available from
Du Pont), nylon in any of its engineered formulations of Nylon 6
and Nylon 66, polyphenylene sulfide (e.g., RYTON.RTM. available
from Chevron Phillips in The Woodlands, Tex.), polyamide (e.g.,
ZYTEL.RTM. available from DuPont), polycarbonate (PC), polyester
(PE), polypropylene (PP), and polyvinyl chloride (PVC) and weather
able engineering thermoplastics such as polyphenylene oxide (PPO),
polymethyl methacrylate, polyphenylene (PPE), styrene-acrylonitrile
(SAN), polystyrene and blends based on those materials.
Furthermore, weatherable thermosetting polymers, such as
unsaturated polyester (UP) and epoxy, may be used.
Some materials described above and elsewhere in this document may
include engineered polymers, which are specifically formulated to
meet certain requirements specific for photovoltaic applications.
For example, certain hybrid block co-polymers may be used.
In certain embodiments, a connector body includes a cavity
configured to fit snugly over another connector body of the
adjacent module. This cavity may have an opening facing towards a
planar surface of the support sheet during installation or, more
specifically, towards another connector body and/or a building
structure. In certain embodiments, the cavity has a conductive pin
positioned within the cavity and acting as a conductive
element.
In certain embodiments, a connector body includes one or more
interlocking features. The interlocking features are configured to
keep one connector body connected to another connector body after
installation. In the same or other embodiments, a connector body
includes one or more sealing features. A connector body may include
one or more conductive elements that are not electrically connected
to the photovoltaic cells of the module. For example, a module may
have bus bar extending throughout the module without making any
direct electrical connections to the cells. In certain embodiments,
one or both connectors are positioned in a moisture flap area of
the module.
Provided also is a method for installing a photovoltaic array. The
method may involve providing first and second BIP modules and
positioning a connector body of one module (e.g., the first module)
over a connector body of the other module (e.g., the second module)
to form an electrical connection between the modules' respective
conductive elements. The first module may be positioned on a
building structure and even attached to the building structure, for
example, by nailing its support sheet to the structure. This module
includes a first connector having a connector body and an arm,
which mechanically connects the body to the support sheet such that
the body is movable with respect to the support sheet at least in a
direction perpendicular to its planar surface. The connector body
includes one or more conductive elements, some of which may be
electrically coupled to a set of photovoltaic cells of the module.
The second module includes a connector also having a connector body
attached to its own support sheet. This connector body similarly
includes one or more conductive elements, some of which may be
electrically coupled to a set of photovoltaic cells of the second
module.
In certain embodiments, one module is movable with respect to
another module in one or more direction parallel to a planar
surface of either module without interfering with one or more
electrical connections between the modules or, more specifically,
between one or more conductive elements of the two modules. In the
same or other embodiments, the process involves dispensing a
sealing material and/or an adhesive material between the two
connector bodies prior to positioning one connector body over the
other one. The method may also include attaching support sheets of
one or both modules to the building structure.
These and other aspects of the invention are described further
below with reference to the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional side view of a building
integrable photovoltaic (BIP) module in accordance with certain
embodiments.
FIG. 2 is a schematic top view of a BIP module in accordance with
certain embodiments.
FIG. 3 illustrates a subset of a photovoltaic array that includes
six RIP modules in accordance with certain embodiments.
FIG. 4 is a schematic illustration of a photovoltaic array
installed on a rooftop of a building structure in accordance with
certain embodiments.
FIG. 5 is a schematic representation of a photovoltaic module
having electrically interconnected photovoltaic cells in accordance
with certain embodiments.
FIG. 6 is a schematic electrical diagram of a photovoltaic array
having three BIP modules interconnected in series in accordance
with certain embodiments.
FIG. 7 is a schematic electrical diagram of another photovoltaic
array having three BIP modules interconnected in parallel in
accordance with other embodiments.
FIGS. 8A-8C are schematic cross-sectional views of two connectors
configured for interconnection with each other in accordance with
certain embodiments.
FIG. 9 is a schematic representation of two building integrable
photovoltaic (BIP) modules prior to making an electrical connection
between these modules in accordance with certain embodiments.
FIG. 10A is another schematic representation of two other BIP
modules prior to making an electrical connection between these
modules in accordance with certain embodiments.
FIG. 10B is a schematic representation of two interconnected BIP
modules in accordance with certain embodiments.
FIG. 11 is a schematic top view of two interconnected BIP modules
illustrating flexibility of their connectors that allows one module
to move with respect to the other module in accordance with certain
embodiments.
FIG. 12 illustrates an example of a connector with two flat
conductive elements surrounded by a seal in accordance with certain
embodiments.
FIG. 13 is a flowchart corresponding to a process for installing an
array of BIP modules in accordance with certain embodiments.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
In the following description, numerous specific details are set
forth in order to provide a thorough understanding of the present
invention. The present invention may be practiced without some or
all of these specific details. In other instances, well known
process operations have not been described in detail to not
unnecessarily obscure the present invention. While the invention
will be described in conjunction with the specific embodiments, it
will be understood that it is not intended to limit the invention
to the embodiments.
Introduction
Building-integrable photovoltaic (BIP) modules are defined as
specially configured photovoltaic modules that are used for
integration into building structures in various parts of buildings,
such as rooftops, skylights, or facades. In certain examples, BIP
modules replace conventional building materials, such as asphalt
shingles. Unlike traditional photovoltaic systems, BIP modules
often do not require separate mounting hardware. As such, installed
BIP modules provide substantial savings over more traditional
systems in terms of building materials and labor costs. For
example, a substantial part of traditional asphalt roof shingles
may be replaced by "photovoltaic shingles." In certain embodiments,
photovoltaic shingles are installed on the same base roof
structures as the asphalt shingles. In fact, a rooftop may be
covered by a combination of the asphalt and photovoltaic shingles.
In certain embodiments, RIP modules are shaped like one or a
collection of asphalt shingles. BIP modules may look and act much
like the asphalt shingles while producing electricity in addition
to protecting the underlying building structures from the
environment. In certain embodiments, BIP modules may be about 14
(e.g., 13.25) inches by about 40 (e.g., 39.375) inches in size and
may be stapled directly to the roof deck through water barrier
roofing cloth, for example. Generally, only a portion of the
photovoltaic shingle is exposed, while the remaining portion is
covered by other shingles. The exposed portion is referred to as
the "shingle exposure", while the covered portion is referred to as
the "flap." For example, the shingle exposure of a 13.25 inch by
39.375 inch shingle may be only about 5 inches wide or, in some
embodiments, about 5.625 inches wide. The length of the shingle
exposure in some of these embodiments may be 36 inches or about
39.375 inches (if side skirts are not used, for example). Other
dimensions of photovoltaic shingles may be used as well.
During installation, BIP modules need to be electrically
interconnected with respect to each other and/or a building
structure. This is typically a very labor intensive operation,
which often requires a separate installation professional and
multiple holes to be made through the building structure for some
traditional BIP module designs. For example, electrical connections
are conventionally made on the inside of the building structure and
wires from each module are fed through the structure through
individual holes. Novel BIP modules and connectors described in
this document substantially simplify the installation process and
provide robust electrical connections without a need for holes
through the building structure that may present a risk to its
integrity. A module includes one or more photovoltaic cells
positioned on a support sheet and two or more electrical connectors
attached to the support sheet. At least two conductive elements of
these connectors are electrically coupled to the photovoltaic
cells. One connector includes a connector body and an arm, which
allows the connector body to move with respect to the support sheet
at least in a direction perpendicular to the support sheet. This
flexibility may be used to electrically interconnect modules as
well as other purposes. Another connector also has a connector
body, which may be flexibly or rigidly attached to the same support
sheet. Positioning two connectors on opposite edges of the module
allows forming a row of electrically interconnected modules.
To provide a better understanding of various features of BIP
modules and methods of integrating connectors with photovoltaic
inserts during module fabrication, some examples of BIP modules
will now be briefly described. FIG. 1 is a schematic
cross-sectional end view (line 1--1 in FIG. 2 indicates the
position of this cross-section) of a BIP module 100 in accordance
with certain embodiments. RIP module 100 may have one or more
photovoltaic cells 102 that are electrically interconnected.
Photovoltaic cells 102 may be interconnected in parallel, in
series, or in various combinations of these. Examples of
photovoltaic cells include copper indium gallium selenide (CIGS)
cells, cadmium-telluride (Cd--Te) cells, amorphous silicon (a-Si)
cells, micro-crystalline silicon cells, crystalline silicon (c-Si)
cells, gallium arsenide multi-junction cells, light adsorbing dye
cells, organic polymer cells, and other types of photovoltaic
cells.
Photovoltaic cell 102 has a photovoltaic layer that generates a
voltage when exposed to sunlight. In certain embodiments, the
photovoltaic layer includes a semiconductor junction. The
photovoltaic layer may be positioned adjacent to a back conductive
layer, which, in certain embodiments, is a thin layer of
molybdenum, niobium, copper, and/or silver. Photovoltaic cell 102
may also include a conductive substrate, such as stainless steel
foil, titanium foil, copper foil, aluminum foil, or beryllium foil.
Another example includes a conductive oxide or metallic deposition
over a polymer film, such as polyimide. In certain embodiments, a
substrate has a thickness of between about 2 mils and 50 mils
(e.g., about 10 mils), with other thicknesses also within the
scope. Photovoltaic cell 102 may also include a top conductive
layer. This layer typically includes one or more transparent
conductive oxides (TCO), such as zinc oxide, aluminum-doped zinc
oxide (AZO), indium tin oxide (ITO), and gallium doped zinc oxide.
A typical thickness of a top conductive layer is between about 100
nanometers to 1,000 nanometers (e.g., between about 200 nanometers
and 800 nanometers), with other thicknesses within the scope.
In certain embodiments, photovoltaic cells 102 are interconnected
using one or more current collectors (not shown). The current
collector may be attached and configured to collect electrical
currents from the top conductive layer. The current collector may
also provide electrical connections to adjacent cells as further
described with reference to of FIG. 5, below. The current collector
includes a conductive component (e.g., an electrical trace or wire)
that contacts the top conductive layer (e.g., a TCO layer). The
current collector may further include a top carrier film and/or a
bottom carrier film, which may be made from transparent insulating
materials to prevent electrical shorts with other elements of the
cell and/or module. In certain embodiments, a bus bar is attached
directly to the substrate of a photovoltaic cell. A bus bar may
also be attached directly to the conductive component of the
current collector. For example, a set of photovoltaic cells may be
electrically interconnected in series with multiple current
collectors (or other interconnecting wires). One bus bar may be
connected to a substrate of a cell at one end of this set, while
another bus bar may be connected to a current collector at another
end.
Photovoltaic cells 102 may be electrically and environmentally
insulated between a front light-incident sealing sheet 104 and a
back sealing sheet 106. Examples of sealing sheets include glass,
polyethylene, polyethylene terephthalate (PET), polypropylene,
polybutylene, polybutylene terephthalate (PBT), polyphenylene oxide
(PPO), polyphenylene sulfide (PPS) polystyrene, polycarbonates
(PC), ethylene-vinyl acetate (EVA), fluoropolymers (e.g., polyvinyl
fluoride (PVF), polyvinylidene fluoride (PVDF),
ethylene-terafluoethylene (ETFE), fluorinated ethylene-propylene
(FEP), perfluoroalkoxy (PFA) and polychlorotrifluoroethane
(PCTFE)), acrylics (e.g., poly(methyl methacrylate)), silicones
(e.g., silicone polyesters), and/or polyvinyl chloride (PVC), as
well as multilayer laminates and co-extrusions of these materials.
A typical thickness of a sealing sheet is between about 5 mils and
100 mils or, more specifically, between about 10 mils and 50 mils.
In certain embodiments, a back sealing sheet includes a metallized
layer to improve water permeability characteristics of the sealing
sheet. For example, a metal foil may be positioned in between two
insulating layers to form a composite back sealing sheet. In
certain embodiments, a module has an encapsulant layer positioned
between one or both sealing sheets 104, 106 and photovoltaic cells
102. Examples of encapsulant layer materials include non-olefin
thermoplastic polymers or thermal polymer olefin (TPO), such as
polyethylene (e.g., a linear low density polyethylene,
polypropylene, polybutylene, polyethylene terephthalate (PET),
polybutylene terephthalate (PBT), polystyrene, polycarbonates,
fluoropolymers, acrylics, ionomers, silicones, and combinations
thereof.
BIP module 100 may also include an edge seal 105 that surrounds
photovoltaic cells 102. Edge seal 105 may be used to secure front
sheet 104 to back sheet 106 and/or to prevent moisture from
penetrating in between these two sheets. Edge seal 105 may be made
from certain organic or inorganic materials that have low inherent
water vapor transmission rates (WVTR), e.g., typically less than
1-2 g/m.sup.2/day. In certain embodiments, edge seal 105 is
configured to absorb moisture from inside the module in addition to
preventing moisture ingression into the module. For example, a
butyl-rubber containing moisture getter or desiccant may be added
to edge seal 105. In certain embodiments, a portion of edge seal
105 that contacts electrical components (e.g., bus bars) of BIP
module 100 is made from a thermally resistant polymeric material.
Various examples of thermally resistant materials and RTI ratings
are further described below.
BIP module 100 may also have a support sheet 108 attached to back
side sealing sheet 106. The attachment may be provided by a support
edge 109, which, in certain embodiments, is a part of support sheet
108. Support sheets may be made, for example, from rigid materials.
Some examples of rigid materials include polyethylene terephthalate
(e.g., RYNITE.RTM. available from Du Pont in Wilmington, Del.),
polybutylene terephthalate (e.g., CRASTIN.RTM. also available from
Du Pont), nylon in any of its engineered formulations of Nylon 6
and Nylon 66, polyphenylene sulfide (e.g., RYTON.RTM. available
from Chevron Phillips in The Woodlands, Tex.), polyamide (e.g.,
ZYTEL.RTM. available from DuPont), polycarbonate (PC), polyester
(PE), polypropylene (PP), and polyvinyl chloride (PVC) and weather
able engineering thermoplastics such as polyphenylene oxide (PPO),
polymethyl methacrylate, polyphenylene (PPE), styrene-acrylonitrile
(SAN), polystyrene and blends based on those materials.
Furthermore, weatherable thermosetting polymers, such as
unsaturated polyester (UP) and epoxy, may be used. The properties
of these materials listed above may be enhanced with the addition
of fire retardants, color pigments, anti-tracking, and/or ignition
resistant materials. In addition, glass or mineral fibers powders
and/or spheres may be used to enhance the structural integrity,
surface properties, and/or weight reduction. The materials may also
include additives such as anti-oxidants, moisture scavengers,
blowing or foaming agents, mold release additives, or other plastic
additives.
In certain embodiments, support sheet 108 may be attached to back
sheet 106 without a separate support edge or other separate
supporting element. For example, support sheet 108 and back sheet
106 may be laminated together or support sheet 108 may be formed
(e.g., by injection molding) over back sheet 106. In other
embodiments back sealing sheet 106 serves as a support sheet. In
this case, the same element used to seal photovoltaic cells 102 may
be positioned over and contact a roof structure (not shown).
Support sheet 108 may have one or more ventilation channels 110 to
allow for air to flow between BIP module 100 and a building
surface, e.g., a roof-deck or a water resistant
underlayment/membrane on top of the roof deck. Ventilation channels
110 may be used for cooling BIP module during its operation. For
example, it has been found that each 1.degree. C. of heating from
an optimal operating temperature of a typical CIGS cell causes the
efficiency loss of about 0.33% to 0.5%.
RIP module 100 has one or more electrical connectors 112 for
electrically connecting BIP module 100 to other BIP modules and
array components, such as an inverter and/or a battery pack. In
certain embodiments, RIP module 100 has two electrical connectors
112 positioned on opposite sides (e.g., the short or minor sides of
a rectangular module) of BIP module 100, as for example shown in
FIGS. 1 and 2, for example. Each one of two electrical connectors
112 has at least one conductive element electrically connected to
photovoltaic cells 102. In certain embodiments, electrical
connectors 112 have additional conductive elements, which may or
may not be directly connected to photovoltaic cells 102. For
example, each of two connectors 112 may have two conductive
elements, one of which is electrically connected to photovoltaic
cells 102, while the other is electrically connected to a bus bar
(not shown) passing through BIP module 100. This and other examples
are described in more detail in the context of FIGS. 6 and 7. In
general, regardless of the number of connectors 112 attached to BIP
module 100, at least two conductive elements of these connectors
112 are electrically connected to photovoltaic cells 102.
FIG. 2 is a schematic top view of BIP module 100 in accordance with
certain embodiments. Support sheet 108 is shown to have a side
skirt 204 and a top flap 206 extending beyond a BIP module boundary
202. Side skirt 204 is sometimes referred to as a side flap, while
top flap 206 is sometimes referred to as a top lap. In certain
embodiments, BIP module 100 does not include side flap 204. BIP
module boundary 202 is defined as an area of BIP module 100 that
does not extend under other BIP modules or similar building
materials (e.g., roofing shingles) after installation. BIP module
boundary 202 includes photovoltaic cells 102. Generally, it is
desirable to maximize the ratio of the exposed area of photovoltaic
cells 102 to BIP module boundary 202 in order to maximize the
"working area" of BIP module 100. It should be noted that, after
installation, flaps of other BIP modules typically extend under BIP
module boundary 202. In a similar manner, after installation, side
flap 204 of BIP module 100 may extend underneath another BIP module
positioned on the left (in the same row) of BIP module 100 creating
an overlap for moisture sealing. Top flap 206 may extend underneath
one or more BIP modules positioned above BIP module 100.
Arrangements of BIP modules in an array will now be described in
more detail with reference to FIGS. 3 and 4.
FIG. 3 illustrates a photovoltaic array 300 or, more specifically a
portion of a photovoltaic array, which includes six BIP modules
100a-100f arranged in three different rows extending along
horizontal rooflines in accordance with certain embodiments.
Installation of BIP modules 100a-100f generally starts from a
bottom roofline 302 so that the top flaps of BIP modules 100a-100f
can be overlapped with another row of BIP modules. If a side flap
is used, then the position of the side flap (i.e., a left flap or a
right flap) determines which bottom corner should be the starting
corner for the installation of the array. For example, if a BIP
module has a top flap and a right-side flap, then installation may
start from the bottom left corner of the roof or of the
photovoltaic array. Another RIP module installed later in the same
row and on the right of the initial BIP module will overlap the
side flap of the initial BIP module. Furthermore, one or more BIP
modules installed in a row above will overlap the top flap of the
initial BIP module. This overlap of a BIP module with a flap of
another BIP module creates a moisture barrier.
FIG. 4 is a schematic illustration of a photovoltaic array 400
installed on a rooftop 402 of a building structure 404 for
protecting building structure 404 from the environment as well as
producing electricity in accordance with certain embodiments.
Multiple RIP modules 100 are shown to fully cover one side of
rooftop 402 (e.g., a south side or the side that receives the most
sun). In other embodiments, multiple sides of rooftop 402 are used
for a photovoltaic array. Furthermore, some portions of rooftop 402
may be covered with conventional roofing materials (e.g., asphalt
shingles). As such, BIP modules 100 may also be used in combination
with other roofing materials (e.g., asphalt shingles) and cover
only a portion of rooftop. Generally, RIP modules 100 may be used
on steep sloped to low slope rooftops. For example, the rooftops
may have a slope of at least about 2.5-to-12 or, in many
embodiments, at least about 3-to-U.
Multiple BIP modules 100 may be interconnected in series and/or in
parallel with each other. For example, photovoltaic array 400 may
have sets of BIP modules 100 interconnected in series with each
other (i.e., electrical connections among multiple photovoltaic
modules within one set), while these sets are interconnected in
parallel with each other (i.e., electrical connections among
multiple sets in one array). Photovoltaic array 400 may be used to
supply electricity to building structure 404 and/or to an
electrical grid. In certain embodiments, photovoltaic array 400
includes an inverter 406 and/or a battery pack 408. Inverter 406 is
used for converting a direct current (DC) generated by RIP modules
100 into an alternating current (AC). Inverter 406 may be also
configured to adjust a voltage provided by BIP modules 100 or sets
of BIP modules 100 to a level that can be utilized by building
structure 404 or by a power grid. In certain embodiments, inverter
406 is rated up to 600 volts DC input or even up to 1000 volts DC,
and/or up to 10 kW power. Examples of inverters include a
photovoltaic static inverter (e.g., BWT10240-Gridtec 10, available
from Trace Technologies in Livermore, Calif.) and a string inverter
(e.g. Sunny Boy RTM.2500 available from SMA America in Grass
Valley, Calif.). In certain embodiments, BIP modules may include
integrated inverters, i.e., "on module" inverters. These inverters
may be used in addition to or instead of external inverter 406.
Battery pack 408 is used to balance electric power output and
consumption.
FIG. 5 is a schematic representation of a photovoltaic module
insert 500 illustrating photovoltaic cells 504 electrically
interconnected in series using current collectors/interconnecting
wires 506 in accordance with certain embodiments. Often individual
cells do not provide an adequate output voltage. For example, a
typical voltage output of an individual CIGS cell is only between
0.4V and 0.7V. To increase voltage output, photovoltaic cells 504
may be electrically interconnected in series for example, shown in
FIG. 5 and/or include "on module" inverters (not shown). Current
collectors/interconnecting wires 506 may also be used to provide
uniform current distribution and collection from one or both
contact layers.
As shown in FIG. 5, each pair of photovoltaic cells 504 has one
interconnecting wire positioned in between the two cells and
extending over a front side of one cell and over a back side of the
adjacent cell. For example, a top interconnecting wire 506 in FIG.
5 extends over the front light-incident side of cell 504 and under
the back side of the adjacent cell. In the figure, the
interconnecting wires 506 also collect current from the TCO layer
and provide uniform current distribution, and may be referred to
herein as current collectors. In other embodiments, separate
components are used to for current collection and cell-cell
interconnection. End cell 513 has a current collector 514 that is
positioned over the light incident side of cell 513 but does not
connect to another cell. Current collector 514 connects cell 513 to
a bus bar 510. Another bus bar 508 may be connected directly to the
substrate of the cell 504 (i.e., the back side of cell 504). In
another embodiment, a bus bar may be welded to a wire or other
component underlying the substrate. In the configuration shown in
FIG. 5, a voltage between bus bars 508 and 510 equals a sum of all
cell voltages in insert 500. Another bus bar 512 passes through
insert 500 without making direct electrical connections to any
photovoltaic cells 504. This bus bar 512 may be used for
electrically interconnecting this insert in series without other
inserts as further described below with reference to FIG. 6.
Similar current collectors/interconnecting wires may be used to
interconnect individual cells or set of cells in parallel (not
shown).
BIP modules themselves may be interconnected in series to increase
a voltage of a subset of modules or even an entire array. FIG. 6
illustrates a schematic electrical diagram of a photovoltaic array
600 having three BIP modules 602a-602c interconnected in series
using module connectors 605a, 605b, and 606 in accordance with
certain embodiments. A voltage output of this three-module array
600 is a sum of the voltage outputs of three modules 602a-602c.
Each module connector 605a and 605b shown in FIG. 6 may be a
combination of two module connectors of BIP modules 602a-602c.
These embodiments are further described with reference to FIGS.
8A-8C. In other words, there may be no separate components
electrically interconnecting two adjacent BIP modules, with the
connection instead established by engaging two connectors installed
on the two respective modules. In other embodiments, separate
connector components (i.e., not integrated into or installed on BIP
modules) be used for connecting module connectors of two adjacent
modules.
Module connector 606 may be a special separate connector component
that is connected to one module only. It may be used to
electrically interconnect two or more conductive elements of the
same module connector.
Sometimes BIP modules may need to be electrically interconnected in
parallel. FIG. 7 illustrates a schematic electrical diagram of a
photovoltaic array 700 having three BIP modules 702a-702c
interconnected in parallel using module connectors 705a and 705b in
accordance with certain embodiments. Each module may have two bus
bars extending through the module, i.e., a "top" bus bar 711 and a
"bottom" bus bar 713 as shown in FIG. 7. Top bus bars 711 of each
module are connected to right electrical leads 704a, 704b, and 704c
of the modules, while bottom bus bars 713 are connected to left
electrical leads 703a, 703b, and 703c. A voltage between the top
bus bars 711 and bottom bus bars 713 is therefore the same along
the entire row of BIP modules 702a-702c.
FIG. 8A is a schematic cross-sectional side view of two connectors
800 and 815 configured for interconnection with each other, in
accordance with certain embodiments. For simplicity, the two
connectors are referred to as a female connector 800 and a male
connector 815. Each of the two connectors 800 and 815 is shown
attached to its own photovoltaic insert, which includes
photovoltaic cells 802 and one or more sealing sheets 804.
Connectors 800 and 815 include conductive elements 808b and 818b,
respectively, which are shown to be electrically connected to
photovoltaic cells 802 using bus bars 806 and 816,
respectively.
In certain embodiments, a conductive element of one connector
(e.g., conductive element 808b of female connector 800) is shaped
like a socket/cavity and configured for receiving and tight fitting
a corresponding conductive element of another connector (e.g.,
conductive element 818b of male connector 815). Specifically,
conductive element 808b is shown forming a cavity 809b. This tight
fitting and contact in turn establishes an electrical connection
between the two conductive elements 808b and 818b. Accordingly,
conductive element 818b of male connector 815 may be shaped like a
pin (e.g., a round pin or a flat rectangular pin). A socket and/or
a pin may have protrusions (not shown) extending towards each other
(e.g., spring loaded tabs) to further minimize the electrical
contact resistance by increasing the overall contact area. In
addition, the contacts may be fluted to increase the likelihood of
good electrical contact at multiple points (e.g., the flutes
guarantee at least as many hot spot asperities of current flow as
there are flutes).
In certain embodiments, connectors do not have a cavity-pin design
as shown in FIGS. 8A-8C. Instead, an electrical connection may be
established when two substantially flat surfaces contact each
other. Conductive elements may be substantially flat or have some
topography designed to increase a contact surface over the same
projection boundary and/or to increase contact force at least in
some areas. Examples of such surface topography features include
multiple pin-type or rib-type elevations or recesses.
In certain embodiments, one or more connectors attached to a BIP
module have a "touch free" design, which means that an installer
can not accidently touch conductive elements or any other
electrical elements of these connectors during handling of the BIP
module. For example, conductive elements may be positioned inside
relatively narrow cavities. The openings of these cavities are too
small for a finger to accidently come in to contact with the
conductive elements inside the cavities. One such example is shown
in FIG. 8A where male connector 815 has a cavity 819b formed by
connector body 820 around its conductive pin 818b. While cavity
819b may be sufficiently small to ensure a "touch free" designed as
explained above, it is still large enough to accommodate a portion
of connector body 810 of female connector 800. In certain
embodiments, connector bodies 810 and 820 have interlocking
features (not shown) that are configured to keep the two connectors
800 and 815 connected and prevent connector body 810 from sliding
outs of cavity 819b. Examples of interlocking features include
latches, threads, and various recess-protrusion combinations.
FIG. 8B is schematic plan view of female connector 800 and male
connector 815, in accordance with certain embodiments. Each
connector 800, 815 is shown with two conductive elements (i.e.,
conductive sockets 808a and 808b in connector 800 and conductive
pins 818a and 818b in connector 815). One conductive element (e.g.,
socket 808b and pin 818b) of each connector is shown to be
electrically connected to photovoltaic cells 802. Another
conductive element of each connector 800, 815 may be connected to
bus bars (e.g., bus bars 809 and 819) that do not have an immediate
electrical connection to photovoltaic cells 802 of their respective
BIP module (the extended electrical connection may exist by virtue
of a complete electrical circuit).
As shown, sockets 808a and 808b may have their own designated inner
seals 812a and 812b. Inner seals 812a and 812b are designed to
provide more immediate protection to conductive elements 808a and
818a after connecting the two connectors 800, 815. As such, inner
seals 812a and 812b are positioned near inner cavities of sockets
808a and 808b. The profile and dimensions of pins 818a and 818b
closely correspond to that of inner seals 812a and 812b. In the
same or other embodiments, connectors 800, 815 have external seals
822a and 822b. External seals 822a and 822b may be used in addition
to or instead of inner seals 812a and 812b. Various examples of
seal materials and fabrication methods are described below in the
context of FIG. 9. FIG. 8C is schematic front view of female
connector 800 and male connector 815, in accordance with certain
embodiments. Connector pins 818a and 818b are shown to have round
profiles. However, other profiles (e.g., square, rectangular) may
also be used for pins 818a and 818b and conductive element cavities
808a and 808b.
FIG. 9 is a schematic representation of two building integrable
photovoltaic (BIP) modules 902 and 912 prior to making one or more
electrical connections between these modules in accordance with
certain embodiments. Module 902 has one or more photovoltaic cells
904 positioned on a support sheet 906. When multiple photovoltaic
cells are provided, the cells are typically interconnected in
series or in parallel. Various examples of photovoltaic cells and
interconnecting techniques are described above. In specific
embodiments, each module has at least ten Copper indium gallium
(di)selenide (CIGS) cells interconnected in series.
Support sheet 906 of module 902 has a planar surface, which is
defined as a front surface of support sheet 906. Support sheet 906
may be made from various materials, such as polyethylene,
polypropylene, thermoplastic rubber, thermoplastic elastomer, and
ethylene propylene diene monomer (EPDM). In certain embodiments,
support sheet 906 is formed during injection molding and formation
of an over-molding around photovoltaic cells 904. In other
embodiments, a support sheet is apart of a back sealing sheet
and/or a front sealing sheet of the module. These two sealing
sheets are used for environmental and electrical protection as well
as for mechanical support of cells 904. One or both sealing sheets
may be made from rigid and/or flexible materials. For example, in
certain embodiments both front and back sealing sheets are made
from rigid glass sheets. In another example, a front sheet is made
from a rigid glass sheet, while a back sheet is made from a
flexible sheet. In yet another example, both sealing sheets are
flexible. Examples of rigid materials include window glass, plate
glass, silicate glass, low iron glass, tempered glass, tempered
CeO-free glass, float glass, colored glass, and the like. In
certain embodiments, one or both of the front and back sheets are
made from or include polymer materials. Examples of suitable
polymer materials, which can be rigid or flexible, include
poly(ethylene terephthalate), polycarbonate, polypropylene,
polyethylene, polypropylene, cyclic polyloefins, norbornene
polymers, polystyrene, syndiotactic polystyrene, styrene-acrylate
copolymers, acrylonitrile-styrene copolymers, poly(ethylene
naphthalate), polyethersulfone, polysulfone, nylons,
poly(urethanes), acrylics, cellulose acetates, cellulose
triacetates, cellophane, vinyl chloride polymers, polyvinylidene
chloride, vinylidene chloride copolymers, fluoropolymers, polyvinyl
fluoride, polyvinylidene fluoride, polytetrafluoroethylene,
ethylene-tetrafluoroethylene copolymer, and the like. A thickness
of the sealing sheet may be between about 1 millimeter and about 15
millimeters or, more particularly, between about 2.5 millimeters
and about 10 millimeters, for example, about 3 millimeters or about
4 millimeters.
Module 902 has a connector 920 that includes a connector body 924
and an arm 922. Arm 922 supports connector body 924 such that
connector body 924 is movable with respect to support sheet 906.
This flexibility allows connector 920 to mechanically and
electrically interconnect with another connector, such as connector
930 of module 912. More specifically, this flexibility allows
connector body 924 to move in a direction substantially
perpendicular to the planar surface of support sheet 906, i.e., in
the up-and-down direction, with respect to support sheet 906.
Connector body 924 and/or connector arm 924 may be made of one or
more of rigid materials some examples of which are described
above.
In certain embodiments, a connector arm is a part of the support
sheet or an extension of the support sheet. For example, the
support sheet may have a partial cut defining an arm and separating
it from the rest of the support sheet. In the same or other
embodiments, a connector arm and other connector components may be
a part of a moisture flap of the module. As shown in FIG. 9, module
902 has a moisture flap 908 extending on one side of photovoltaic
cells 904. Module 912 is shown to have a similar moisture flap 918
extending along the same side of cells 914. Connectors 920 and 930
are positioned in areas of respective moisture flaps 908 and 918.
Connectors 920 and 930 may be sufficiently thin to fit under
another module extending over moisture flaps 908 and 918 after
installation. In certain embodiments, connectors are configured to
fit into a ventilation channel of the other module.
Module 912 has one or more photovoltaic cells 914 positioned on a
support sheet 916. Module 912 also has a connector 930 including a
connector body 934 attached to support sheet 916. Connector body
934 includes one or more conductive elements 936. More
specifically, FIG. 9 illustrates two pin-type conductive elements
936 positioned in a cavity of connector body 934. At least one of
conductive elements 936 may be electrically coupled to photovoltaic
cells 914. Connector 930 is configured to form one or more
electrical connections with connector 920 defined by the respective
conductive elements of the connectors. Overall, modules 902 and 912
may have similar designs that allow forming a row of interconnected
modules. Specifically, module 902 may have connector 920 on one
edge and a connector similar to connector 930 on the other opposite
edge. Using these two connectors, module 902 may form electrical
connections with two other modules.
As mentioned above, arm 922 is used to flexibly support connector
body 924 with respect to support sheet 906. In certain embodiments,
arm 922 comprises a pivoting axis 926 that allows a portion of arm
922 or entire arm 922 to move with respect to support sheet 906.
Pivoting axis 926 may be positioned at the interface with support
sheet 906 as shown in FIG. 9, which allows entire arm 922 to pivot
with respect to support sheet 906. In other embodiments, a pivoting
axis may be positioned at some point along the arm's length, which
may divide the arm into a stationary portion and a moving portion.
A pivoting axis may be substantially perpendicular to the length of
the arm. A pivoting axis may be formed by thinning one or more arm
components, providing partial cuts, or otherwise making a portion
of the connector more flexible than other portions.
In other embodiments, an arm may be made from a flexible material
and include one or more flexible conductive pathways that allows
the arm to bend along its length during installation. FIG. 10A is a
schematic illustration of two photovoltaic modules 1002 and 1012
prior to their interconnection in accordance with certain
embodiments. Modules 1002 and 1012 may have support sheets 906 and
916 and photovoltaic cells 904 and 914 similar to the ones
described above in the context of FIG. 9. Connector bodies 924 and
934 may be also similar. However, a connector arm 1022 of module
1002 is configured to bend in a direction away from the planar
surface of module 1002. While bending, arm 1022 may transform from
a straight rectangular shape to an arc similar to the one shown in
FIG. 10A. This bending allows for connector body 934 of module 1012
to be positioned under connector body 924 of module 1002. Connector
body 924 then pushed towards connector body 934 to form electrical
connections between their respective conductive elements as shown
in FIG. 10B. In certain embodiments, an arm has a pivoting axis and
is still flexible along its length.
A connector body may have a cavity configured to fit snugly over a
connector body of an adjacent module. For example, FIGS. 10A and
10B illustrate connector 924 having a cavity 1050 to fit around
connector 934. Cavity 1050 has an opening 1052 facing downwards,
i.e., towards a planar surface of support sheet 906 or more
specifically towards a building structure, in the installed
position shown in FIG. 10B. This design helps to prevent moisture
from getting into a contact area between two connector bodies 924
and 934. One or more conductive elements of connector body 924 may
be shaped as pins and extend within cavity 1050. Opening 1052 of
cavity 1050 may be sufficiently small to enhance product safety by
preventing accidental contact with the conductive elements. In
certain embodiments, such openings may be provided on other
corresponding connectors to allow for "touch-safe" designs.
In addition to flexibility in the up-and-down direction described
above in the context of FIGS. 9, 10A and 10B, one or both
connectors may have flexibility in other directions, for example,
in various directions parallel to the planar surface. FIG. 11 is a
schematic top view of two interconnected BIP modules 1112 and 1114
in accordance with certain embodiments. Module 1112 may move with
respect to module 1114 in a direction 1102 and/or a direction 1104
while retaining all electrical connections between the two modules.
Flexibility along these directions may be needed during
installation to interconnect two slightly misaligned BIP modules
and/or during operation to accommodate slight movements caused by
thermal expansion and other reasons. In certain embodiments, the
flexibility provided by the two connectors is at least about 1
millimeter in direction 1102 and/or at least about 1 millimeter in
direction 1104. More specifically, the flexibility between two
modules 1112 and 1114 is at least about 2 millimeters in direction
1102 or, more specifically, at least about 5 millimeters, or even
at least about 20 millimeters. In the same or other embodiments,
the flexibility between two modules 1112 and 1114 is at least about
2 millimeters in direction 1104 is at least about 2 millimeters or,
more specifically, at least about 5 millimeters, or even at least
about 20 millimeters.
This flexibility may be provided by one or both connector arms 1122
and 1132. Arm 1122 is used to attach connector body 924 to support
sheet 906. Likewise, arm 1132 is used to attach connector body 934
to support sheet 916. In certain embodiments, a two-module
interconnection has only one flexible arm or one arm at all. For
example, connector 934 may be attached directly to support sheet
916 without an arm or any other extension between connector 934 and
support sheet 916.
In certain embodiments, arm 1122 and/or arm 1132 are sufficiently
flexible to allow their respective connector bodies elements 924
and 934) to move at least about 1 millimeter with respect to their
respective support sheets (elements 906 and 916) in direction 1102
and/or direction 1104 or, more specifically, at least about 2
millimeters, about 5 millimeters, or even at least about 20
millimeters. Direction 1104 may be also defined as a direction
parallel to a length of a connector arm. Direction 1102 may be
defined as a direction perpendicular to a length of an arm and
parallel to a planar surface of the support sheet.
In certain embodiments, a connector or, more specifically, a
connector body has one or more interlocking features for
interlocking with another connector body of an adjacent module
during installation. For example, a connector body has one or more
protrusions extending into its cavity. When another connector body
is inserted into this cavity, the protrusion may be first
compressed but then extended behind other protrusions or edges
effectively preventing this second connector body from sliding
outside of the cavity. The interlocking features may be configured
to require a tool for disconnection of the modules.
A connector body may also include a seal configured for protecting
conductive elements of the connector from moisture. In certain
embodiments, a seal is positioned inside the cavity and configured
to form a mechanical contact with a top edge of another connector
body inserted into the cavity during installation. The seal may be
formed using an O-ring or other sealing components and materials,
e.g., silicone sealant, butyl rubber inserts.
In certain embodiments, connectors do not have a cavity-pin design
as discussed above. Instead, an electrical connection may be
established when two substantially flat surfaces contact each
other. FIG. 12 illustrates an example of a connector 1200 with two
flat conductive elements (contacts) 1202 and 1204 (facing upwards)
surrounded by a seal 1206 in accordance with certain embodiments.
The seal may be a rubber O-ring in a groove surrounding the
contacts to conform the O-ring for engagement with a corresponding
seal-forming surface on a counterpart connector element, for
example. Connector 1200 may be used to establish two separate
electrical connections with a similar connector that has conductive
elements (facing downwards and towards conductive elements 1202 and
1204). Conductive elements 1202 and 1204 may be substantially flat
or have some topography designed to increase a contact surface over
the same projection boundary and/or to increase contact force at
least in some areas. Examples of such surface topography features
include multiple pin-type or rib-type elevations or recesses.
Installation Examples
FIG. 13 is a flowchart corresponding to a process 1300 for
installing an array of BIP modules in accordance with certain
embodiments. Process 1300 may start with providing two BIP modules,
i.e., a first module and a second module, in operation 1302.
Various examples of BIP modules are described above. One or both
modules may be attached to a building structure and/or electrically
interconnected with one or more other BIP modules. In either case,
the two modules are typically substantially aligned with respect to
each other prior to operation 1306 such that their electrical
connectors can establish a contact. As described above, the
connectors may be sufficiently flexible in one or more directions
substantially parallel to a planar surface of the modules to
compensate for some misalignment or movement of the modules.
In certain embodiments, a sealing and/or bonding material (e.g.,
silicone based material) are dispensed over the protrusion member
of the first module and/or into the channel of the second module
during an optional operation 1304. Process 1300 may continue with
positioning a connector of one module over another connector of the
adjacent module in operation 1306. For example, a connector body of
the first module may be fitted over a connector body of a second
adjacent module. In certain embodiments, the first connector body
has a cavity to receive the second connector body. When the two
connectors are positioned into their respective installed
positions, electrical connections between their respective
conductive elements are established. The two connector bodies may
also be interlocked during this operation.
Process 1300 may proceed with attaching one or both modules to the
building structure in an optional operation 1310. For example, a
top moisture flap of one or both modules may be nailed, screwed,
glued, or otherwise attached to the building structure. Various
operations of process 1300 may be repeated for one or more other
BIP modules to form a row of mechanically and electrically
interconnected BIP modules (decision block 1312)
CONCLUSION
Although the foregoing invention has been described in some detail
for purposes of clarity of understanding, it will be apparent that
certain changes and modifications may be practiced within the scope
of the appended claims. It should be noted that there are many
alternative ways of implementing the processes, systems and
apparatus of the present invention. Accordingly, the present
embodiments are to be considered as illustrative and not
restrictive, and the invention is not to be limited to the details
given herein.
* * * * *